Method of weaving of closed structures with intersecting walls. RU patent 2505632.

FIELD: textiles, paper.

SUBSTANCE: woven preform for fiber-reinforced composite material comprises horizontal layers of woven fabric and vertical layers of woven fabric, woven integrally with the horizontal layers. In addition, the vertical layers extend in the form of structural elements between the horizontal layers, and the horizontal layers and vertical layers form the through cells in the preform.

EFFECT: preform has a continuous annular reinforcement in each cell formed by circular weaving of weft fibers.

23 cl, 17 dwg

The technical field

The present invention relates to a woven billets for reinforced composite materials and, in particular, to the way native textile fiber of preparations, containing closed perimeters with overlapping elements in the interior.

All specified in the present description patents, patent applications, documents, links, instructions, descriptions, technical characteristics of the products and the technological maps included in the text of this report, and can be applied in the practical use of the invention.

The level of technology

Currently, the use of reinforced composite materials for the manufacture of structural components widespread, in particular in the areas of applications, in which the desired characteristics are lightness, strength, rigidity and thermal stability, independence design and the possibility . Such components are used, for example, in aviation, aerospace, and satellite industries, the entertainment industry (for example, racing boats and cars) and other areas.

Typically, these components include reinforcing materials, placed inside the matrix materials. Reinforcing component can be made on the basis of materials such as glass, carbon, ceramics, aramid, polyethylene and/or other materials with the necessary physical, thermal, chemical and/or other properties, most of which is high strength at the critical load. When using reinforcement materials, which ultimately form a component part of the finished component, the finished composite component give the required characteristics of these materials, such as the very high strength. Usually the components of reinforcing materials can be made woven, knitted, non-woven or may have other required structure and form for the armoring of blanks. Normally pay special attention to the optimal use of characteristics, to ensure the selected reinforcing materials. As a rule, such reinforcing procurement combine with the matrix material for the formation of ready-made components or manufacturing of production of materials for obtaining ultimately finished components.

After the formation of the required reinforcement of the workpiece to it and inside it can be added matrix material in such a way that reinforcing procurement is usually enclosed in a matrix material, as a matrix material fills the gaps between the component parts of the reinforcement of the workpiece. As a matrix material can be used in a variety of materials such as epoxy, polyester, vinyl ester, ceramics, carbon, and/or other materials that also have the requisite physical, thermal, chemical and/or other properties. Materials used as ceramic materials may or may not be similar materials reinforcing procurement, and may or may not have similar physical, chemical, thermal, or other properties. However, usually as a matrix material not use the materials of similar materials reinforcing procurement, or material with similar physical, chemical, thermal or other properties, because usually the main task when using composite materials is obtaining a finished product mix of characteristics that cannot be obtained by means of one of the constituent material. Are so used in conjunction with each other, reinforcing procurement and matrix material can then be solidified and stable at the same stage of heat curing or by other known methods, and then processed at other stages to obtain the desired component. It should be noted that after curing at this stage cured, the mass of the matrix material is usually very well-connected with the reinforcing material (for example, with a reinforcing the workpiece). Due to the load applied to the finished component, in particular, through its matrix material that acts as a binder between the fibers can be effectively transmitted to a reinforcing material procurement and retained by them.

Often there is a need to manufacture components, which form differs from the simple geometrical forms, such as on the merits of the plates, sheets, rectangles, squares, etc. One of the ways of manufacturing of such component is the combination of simple geometric forms into more complex the required forms. One such typical combination is performed by connection is made as described above reinforcing preparations at an angle to each other (usually at a right angle). Usually the objectives of this angular placement connected reinforcing blanks is to obtain the required form for the formation of reinforcing procurement, containing at least one end wall, or increasing the strength of the resulting combination of billets and reinforcing the composite structure of relative deformation or failure under the action of external forces, such as pressure or load. In any case, an additional challenge is the implementation of each connection between components as more durable. Because of the need for very high-strength components themselves reinforcing procurement fragility of the connection is in fact a weak link in the «chain» of the structure.

In the prior art relating to these types of structures, required final form is received by the superposition of the individual layers of fabric type stickiness or individual layers of the prepreg. Received laminated billet then subjected to compressed using resin (in the case of tissue containing amplifier stickiness) or moldable vacuum bag with a drying (in the case of the prepreg). Patent US 5,451,448 refers to the composite multilayer flexible enveloping insulation containing upper woven layer having layers of continuous woven material, the lower woven layer, high-temperature insulation and if necessary layers and periods reflecting the screen, and all the components of reinforced through the use of woven ceramic material. Upper and lower woven layers are fixed to each other by means of double-knitted weave woven ceramic material at an angle relative to the surface of the top-woven layer or lower woven layer, resulting in between the top and bottom layers and double-knitted interlacing intervals are formed, having a form of a triangular prism or trapezoidal prism.

In patent US 6,418,973 offered woven preparation for a ceramic composite material, with layers of interwoven strands of fibrous material and structural elements, passing between these layers. Structural elements can be a wall, which, together with layers form the grooves. According to the revealed in the specified patent method of procurement is woven with the required distances between individual sheets or layers so that these sheets are actually located on a predetermined distance from each other during weaving. This not only limits the size and shape of the obtained structures, but also does not allow for easy production on normal loom. In addition, procurement, formed according to the specified patent, has not closed cells on its outer edges, and trajectory weft threads cannot be selected in a way to form a continuous ring reinforcement in each cell, resulting on the outer edges and patterns are formed open cells and cells that have lower strength relative internal pressure. Thus, the technical level there is a need to create woven blanks with closed cells on the outer edges and continuous ring reinforcement in each cell procurement and method of manufacture of such preparations.

The present invention overcomes the shortcomings of the technology and provides additional benefits, such as less labor intensive manufacturing woven procurement achieved by using a special technology of flat textile machinery by which a first form blank, and then deploy it to obtain its final form.

The essence of the invention

The present invention offered woven procurement for reinforced composite materials and method of its manufacture. In particular, the present invention is proposed the method of machine textile fibre preforms for composite materials with the polymer matrix containing closed perimeters with overlapping elements in the interior.

One variant of realization of the present invention relates to a method for the manufacture of fiber-reinforced composite material, which includes the stages of the formation of a piece by a joint textile horizontal layers with vertical layers and disclosure blanks after receiving it in such a way that the vertical layers takes place in the form of structural elements between horizontal layers, and horizontal layers together with vertical layers form the inside of the workpiece through the cell. Woven workpiece can be filled polymeric matrix material by injection molding or chemical infiltration in the vapour phase. The workpiece can be with a closed perimeter and closed cells on the outer edges with the help of a circular weaving filling fibers. The cells are in the main direction (if the outer edges are formed by a circular woven weft fibers) or the weft direction and can be performed in a square or rectangular form. Billet form so, that it has a continuous ring reinforcement in each cell is formed by a circular woven weft fibers.

Accordingly, the present invention is the fixing of all fibers in relation to each other in the joints and thus to avoid located between the individual layers of resin layers available famous layered composite materials that can eliminate the possibility of a stratification and provides increased resistance to damage.

Another object of the present invention is to ensure the continuity of all fibers in the horizontal wall of the workpiece while passing through the vertical walls and Vice versa, so it may be increased strength of the structure at the intersections.

Another object of the present invention is the manufacture of blanks so that the weft fiber at the inner wall are woven into the outer wall that can improve strength and resistance to damage.

Another object of the present invention is the exception of almost all the manual steps required for obtaining these structures in the known methods of manufacturing of layered structures. The proposed workpiece is woven in the required form and placed in the mold as a single whole, that allows to reduce time and cost of manufacturing.

Another object of the present invention is to exclude additional phases associated with the connection of structural components, by manufacturing procurement with improved performance and efficiency of the design at a lower cost manufacturing.

Another object of the present invention is the exclusion of secondary stage of trimming the edges so that along the edge is not material to be circumcised, that allows to reduce time and cost of manufacturing; the object of the present invention is to remove the need for the amplifier stickiness, which eliminates the potential shortcomings associated with the incompatibility with the basic resin.

Another objective of the present invention is to provide billets for use in composite structures, which do not require drilling the holes for screws or rivets, usually used for connection of metal components with the aim of forming composite metal structures.

Another objective of the present invention is to provide blanks with considerable resistance in a wide range of temperatures, which makes not change their size and shape, as in the case of well-known metal structures.

Another objective of the present invention is to provide piece, which made as in the main direction and in the direction of a duck. Thus, complex forms of all sizes can be obtained on the normal loom. Woven harvesting according to the present invention, perform , then deploy to obtain the final form of a structure to receive a greater number of types of structures formed in accordance with the method proposed.

The present invention can be used for various applications, such as, without limitation, heat exchangers in which the fluid passes through open channels, structural panel with channels, allowing freely to lay the wiring and other elements such as the hydraulic lines, and avionics systems for the disposal of the dipole reflectors, in which containers with dipole reflectors are loaded into open channels.

These and other challenges and advantages will be obvious from the description of the present invention. Fiber reinforced structure can be on a regular weaving machinery, and then folded into a ready form before filling resin without the appearance of deformation fibers.

To better understand the essence of the present invention, its advantages and the tasks solved with it below is the detailed description of examples of preferred options for its implementation, that are explanatory, but not restrictive.

The terms «fiber» and «thread» in this description are interchangeable and have the same value. The terms «containing» and «contains» in this description can mean «include» and «includes» or may have the meanings ascribed to them in the patent law of the United States. The terms «consisting essentially of» and «consists essentially of» when used in formula of the invention shall have the meaning ascribed to them in the patent law of the United States. Other aspects of the present invention disclosed in the following description, or become apparent (and included in the scope of the present invention).

Brief description of drawings

Drawings attached to better understand the essence of the invention and are part of this description, illustrate the different variants of realization of the invention and together with this description are used for the disclosure of the principles of the invention.

Figure 1(a)-(C) show the stages of the formation of cross connection of the woven procurement according to one aspect of the invention;

figure 2(a)-(b) shows the stages in the formation of a woven procurement according to one aspect of the invention;

figure 3(a)-(C) shows the cross-section of blanks, illustrate the stages of the formation of procurement according to one aspect of the invention;

figure 4(a) shows a typical sequence or trajectory weft threads, which in the form of should filling thread, according to one aspect of the invention;

figure 4(b)-(C) shows the cross-section of woven procurement in the direction of duck according to one aspect of the invention;

figure 5 shows the required woven procurement, having woven side walls, closed cells on both edges and continuous reinforcement ring in each cell, according to one aspect of the invention;

6(a)-(b) shows the cross section of woven workpieces with woven side walls, closed cells on both edges and continuous ring reinforcement in each cell, according to one aspect of the invention;

figure 7(a)-(b) shows the woven procurement, which has woven side walls, closed cells on both edges and continuous ring reinforcement in each cell, according to one aspect of the invention; and

on Fig.8 shows a typical sequence or trajectory weft threads for harvesting with three horizontal cells and three vertical cells according to one aspect of the invention.

A detailed description of the preferred options for the implementation of

Below is a detailed description of the invention with reference to the accompanying drawings, showing the preferred options for its implementation. However, the present invention may have various other options for implementation, and is not limited disclosed in this description of variants of realization. These options shown implementation are given more for completeness of this report, and fully disclose the amount of the invention for specialists in the field.

In the following description of the same or corresponding parts shown on the drawings, use identical positions. In addition, it should be noted that in the following description, terms such as «vertical», «horizontal», «outer»and «inner» and the like, used solely for illustrative purposes and are character.

Figure 1(a)-(C) detail shows the stage of the formation of cross connection of 60 in material or workpiece 50 according to one variant of the invention, in which the weft threads are one internal wall to another inner wall inside the workpiece. In particular, figure 1(a) shows two layers of material 50 formed weave two main layers of fibers/yarns 30, 40 with two layers of filling fibers/yarns 10, 20. Thread 30 twist only with 10 threads on the desired network with the formation of the upper layer and the thread 40 twist with 20 threads on the desired network with the formation of the lower layer of material 50 to obtain the desired height h of the inner vertical wall and the required length of 1 internal horizontal walls of the workpiece. The height h of the inner vertical wall and the required length of 1 internal horizontal wall is determined on the basis of the required final size of produced billets. After receiving the desired height h and the required length of 1 thread 30 mutually change positions with 40 threads, resulting yarn 40 are on the top layer, and the threads of 30 are on the bottom layer of the material. The thread 10, 20 retain their positions, so that thread 10 is now twist off 40 threads, and thread 20 twist with 30 threads. It should be noted that two of woven material layer 50 continuously pass through each other in the main and weft threads/fibers, and such integrity is maintained throughout the structure.

After the formation of the material 50 workpiece removed from the loom as a flat sheet. When the workpiece turn in the directions shown in figure 1(b), at the intersection receive continuous fiber elapses without breaks in the main and weft threads that provides high durability of connection of 60.

Figure 3(a)-(C) shows the cross section of the billet 150, illustrate the stages obtain the final form of this procurement. In particular, figure 3(a) shows the procurement 150 after its receipt and removal of the loom. Figure 3(b) shows the blank section 150 when it is partially deployed, and figure 3(C) shows a blank section 150 in its final form. Although the Shuttle looms considered to be the most suitable for the manufacture of the above forms of preparations, other textile technology, such as beading, and rapier weaving machines can be used for the manufacture of woven procurement according to the present invention. Schema weave, such as , satin, twill weave, etc. can be selected depending on the thickness and density of the workpiece.

Figure 4(a)-(C) shows one variant of realization of the present invention, which is a way of formation of woven procurement 250 using one fillings 200, which passes through the whole structure of the workpiece. thread twist in the form of with at least two layers of warp threads with the formation of the workpiece 250 closed, oriented mainly towards grooves or cells 220. A typical sequence or trajectory weft threads, which as such should be thread-200, is shown in the illustrations stages 1-8 shown in figure 4(a). The material in this case is woven so that fiber/thread 200 was sustained in the circumferential direction, and the obtained structure had closed the edge on all sides of the workpiece 250 when you expand, as shown in cross-section, shown in figure 4(C). Length l 1 procurement 250 is limited only by the width of the loom, while the height of the hi walls can be selected virtually any, because when removed from the loom procurement 250 is continuous in the main direction, as shown in figure 4(b). Figure 5 shows a blank section 250, has woven side walls, closed cells 220 on both edges and continuous ring reinforcement in each cell.

One variant of realization of the invention is a method of machine textile fiber procurement 100, consisting of closed perimeters with overlapping elements in its inner part. Workpiece 100 woven flat, as shown in figure 7(a), and then deploy to obtain a cellular structure, as shown in figure 7(b). Textile carried out on the Shuttle loom so that fiber/thread 110 is continuous on the intersection of the inner walls, resulting receive closed edge on all sides of the workpiece 100, as shown in figure 7(b). On Fig.8 shows a typical sequence or trajectory weft threads to obtain shown in Fig.6(a) procurement 450 with three horizontal cells 445 and three vertical cells 445. It should be noted that, as shown in figure 6(a), fiber/ thread woven continuously from the inner walls of the 400 V external walls 410 with the formation of a T-shaped connection 370 and from the inner walls of the 400 in the inner walls of the 400 with the formation of cross connection 360 respectively. It should also be noted that, as shown in Fig.8, the full cycle scheme of weaving is divided into five stages, and on two stages horizontal inner walls of the 400 weave into the outer wall 410, the other two stages of vertical inner walls of the 400 weave into the vertical outer wall, and another stage of the fiber is made, continuously passing through all external walls. If necessary, the fifth stage can be further replicated to increase the thickness of the external walls of relative thickness of the inner walls.

Five stages of weaving fillings can appear in any order. As a schema weaving in the main direction can be used any scheme which provides for the registration of all filling fibers relative to each other (i.e. , satin, twill weave etc). The scheme shown in Fig.8, corresponds to the procurement, consisting of one layer of the framework in each wall. Similarly, can be obtained procurement, containing several layers framework in each wall. In this case, the trajectory shown threading the fibers must be repeated once for each layer fundamentals and basics of fiber must be received by the scheme, which provides for the registration of all layers relative to each other (i.e. cross-cutting thickness corner mutual fixation, end-to-end on the thickness of the orthogonal mutual fixation, mutual fixation of one layer relative to another etc). For example, in cross-thickness corner mutual fixation of the main fiber run through the whole thickness of preparation under an angle determined by the distance between the weft threads. The penetrating thickness of the orthogonal mutual fixation of the main fiber pass through the entire thickness of the workpiece between adjacent columns weft threads so that end-to-end component thickness of more or less perpendicular to the surfaces of tissues. This type of structure is usually contains a stress basis, which simply passes between two layers of filling threads without weave. Under mutual fixation of one layer relative to another staple fibers are only partially through the thickness of the workpiece, that provides for the registration of at least two layers relative to each other. The main fiber usually have the same angle fixing that in the case of corner mutual fixation, but can also be orthogonal. For example, layer 1 in the harvesting can be fixed relatively layer 2, layer 2 layer 3 etc. One variant of realization of the present invention is a method of formation of three-dimensional procurement 350 containing two woven external walls of the 320 and at least one woven inner horizontal wall 330, as shown in figure 6(b). Wall 320, 330 connected to each other with a cloth interior vertical walls 340. Wall 340 may attend or not to attend the outer edges of the vertical billet 350. The resulting structure is a woven workpiece 350 with rigid connections 360, 370, as shown in figure 6(b). 6(a) shows a modification of the implementation of this option, in which the procurement 450 contains at least four located at intervals layer 410-440 with vertical walls 400 passing between these layers, the layers and these walls form a grooves 445, passing in the main direction of the structure.

From the formed according to the invention of fiber procurement can be obtained composite structural component through means such as injection pressing, using tar or chemical infiltration in the vapour phase. Thus, the invention according to one alternative implementation is a fiber-reinforced composite material.

The typical applications of finished structures are applications in which you want to increase rigidity in two directions (i.e. the Foundation of reinforced panels), and applications in which you must have United the separate parts. The proposed procurement can be used in many fields of application, such as, without limitation, heat exchangers in which the fluid passes through open channels, structural panel with channels providing seamless laying electrical wiring and other items, such as hydraulic lines, and aircraft system ejection dipole reflectors, in which containers with dipole reflectors placed in open channels.

Some of the advantages of the present invention in the prior art will consist in the following:

- All the fibers are fixed relative to each other in the joints, which allows to eliminate located between the individual layers of resin layers available famous layered composite materials due to which the possibility of stratification and increased resistance to damage.

- On the inner walls of weft fiber horizontal wall continuously pass through vertical walls and Vice versa, that allows to increase the strength. Connection in the intersection of two inner walls referred to as cross-connection 360 and shown in Fig.6(a)-(b).

- External walls weft fiber inner wall of woven into the outer wall, due to which the increased strength and resistance to damage. Connection in the intersection of the inner wall and outer wall is called the T-junction 370 and shown in Fig.6(a)-(b).

- By means of the proposed method are eliminated virtually all manual operations are required to obtain these structures in the known methods of manufacturing of layered structures. Workpiece receive in the required form and placed inside a mold in the form of one whole, thus reducing the time and cost of manufacturing.

6. Fiber-reinforced composite material containing woven workpiece with horizontal layers of woven fabric and vertical layers of woven material, woven as a whole, together with the horizontal layers, vertical layers takes place in the form of structural elements between horizontal layers, and horizontal layers and vertical layers form in procurement through the cell, and the preparation has a continuous ring reinforcement in each cell is formed by a circular weaving filling fibers.

7. Material 6, additionally contains a polymer matrix material that fills the woven material.

8. Material 6, in which harvesting has a closed perimeter with closed cells on the outer edges, formed by a circular weaving filling fibers.

9. Material 6, in which the cells are mainly direction.

10. Material 6, in which the cells are in the direction of a duck.

11. Material 6, where cells are made square or rectangular.

12. A method of manufacturing fiber-reinforced composite material containing the stages at which shape the workpiece by textile horizontal layers as one whole, together with vertical layers, and deploying the workpiece after you receive it so that vertical layers are held in the form of structural elements between horizontal layers, horizontal layers and vertical layers form in procurement through the cell, and the preparation has a continuous ring reinforcement in each cell is formed by a circular weaving filling fibers.

13. The method according to section 12, according to which woven workpiece additionally filled polymeric matrix material.

14. The method according to item 13, according to which the filling is carried out by injection molding or chemical infiltration in the vapour phase.

15. The method according to section 12, according to which the workpiece receive so that it had a closed perimeter with closed cells on the outer edges, by weaving filling fibers in the circumferential direction.

16. The method according to section 12, according to which the cells are mainly direction.

17. The method according to section 12, according to which the cells are in the direction of a duck.

18. The method according to section 12, according to which cells perform square or rectangular.

19. Method of manufacturing of woven blanks for fiber-reinforced composite material containing the stages at which: woven horizontal layers as one unit together with the vertical layers for the formation of a workpiece, unfold the workpiece after you receive it so that vertical layers are held in the form of structural elements between horizontal layers, horizontal layers and vertical layers form in procurement through the cell, and preparation has a continuous ring reinforcement in each cell is formed by a circular weaving filling fibers.

20. The method according to .19, according to which the workpiece is woven in such a way that it had closed perimeter with closed cells on the outer edges, by weaving filling fibers in the circumferential direction.

21. The method according to .19, according to which the cells are mainly direction.

22. The method according to .19, according to which the cells are in the direction of a duck.

23. The method according to .19, according to which cells perform square or rectangular.